Method for producing connecting ends on metal hoses and hose piece comprising such connecting ends

ABSTRACT

Connecting ends on a hose piece comprising several metal layers, in particular a strip wound metal hose piece, are produced by fixing the overlapping metal layers of a hose of larger length or of an endless hose in the region of the point of separation through welding and subsequently cutting off the hose piece from the longer hose or the endless hose. For simple and inexpensive fixing of the metal layers in the region of the point of separation, a welding seam is generated which extends through at least part of the periphery of the hose or about its entire periphery, using roller seam welding. The hose piece can subsequently be separated along the welding seam obtained in this manner, e.g. along its central line, thereby ensuring permanent and reliable fixing of the metal layers in the region of the connecting end.

This application is a divisional of Ser. No. 10/934,417 filed on Sep. 7,2004 now U.S. Pat. No. 7,111,770 and also claims Paris Conventionpriority of DE 103 42 353.2 filed Sep. 12, 2003 the complete disclosuresof which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The invention concerns a method for producing connecting ends on a hosepiece having several metal layers, in particular, a strip wound metalhose piece, by fixing the overlapping metal layers of a hose having alarger length or of an endless hose in the region of the point ofseparation through welding to subsequently separate the hose piece fromthe longer hose or the endless hose. The invention also concerns a hosepiece, in particular, a strip wound metal hose piece which comprisesseveral metal layers and at least one connecting end in the region ofwhich at least regions of the overlapping metal layers are weldedtogether.

Hoses of this type comprising overlapping metal layers are used, inparticular in the form of annular or helically strip wound hoses, asconduit elements in exhaust pipes of automotive vehicles. Due to theirabove-mentioned construction, they can accommodate certain lengthvariations, as well as the bending and twisting which usually occurduring operation of automotive vehicles, e.g. due to thermal expansionor vibration.

These conduit elements are manufactured, in particular, through helicalwinding of one or more layers of a metal strip. The positive connectionof the neighboring regions of the strip or layers is effected throughU-shaped profiles or folds. The production lines for such hoses areeither endless or produce at least hose sections having a length ofseveral meters.

For further processing, the strip wound hoses must be cut to a desiredlength. This separating process may not be effected by merely cuttingperpendicularly to the hose axis, since fixation of neighboring layerswould be partially destroyed and the strip end would burst open due toits internal tension leading to sharp tips or triangular protrusions atthe strip end. Should a hose piece have such burst-open connecting ends,it cannot be further processed and must be rejected. Later fixing of theburst-opened metal layers in the region of the burst-open connectingends is, in particular, not possible in practice, since the metal layersare exposed to bending loads.

In order to fix the connecting ends before separating off a hose piecefrom the longer hose or from an endless hose, the metal layers of thehose are conventionally fixed only mechanically in the region of theconnecting ends (EP 1 281 904 A2). This may be effected throughpressing, embossing, imprinting etc., of at least regions thereof. Thisrequires, however, relatively expensive tools which must also be adaptedto the respective hose geometry. Moreover, permanent fixing of the metallayers which would allow, in particular, later widening of the hosepiece in the region of the connecting ends as is required for adjustmentto the pipe diameter of neighboring pipe elements, is not possible inpractice.

DE 44 11 246 A1 and EP 0 674 964 A1 describe a method for producingconnecting ends on metal hoses of the above-mentioned type by laserwelding a large number of welding points in the form of a stitch seam tofix the metal layers of an endless hose in the region of thesubsequently produced connecting ends. Subsequent separation of the hosepiece is effected by laser beam cutting.

One disadvantage is the substantial splashing during the required pointwelding of very oily and coated metal strips which can soil theprocessing optics and gas conduits. Moreover, two neighboringapproximately parallel stitch seams or, at considerably reduced speed,one stitched seam must be produced, having a relatively large weldingpoint diameter. This process is time consuming and therefore expensive.If the welding points have similar separations, there is always thefundamental risk that small residual triangular protrusions or nubs areformed after subsequent cutting off of the hose piece. The welded stitchseam at the terminating end of the strip wound hose tends to tear duringa subsequent widening or calibration process leading to incompletefixation in the region of the connecting ends. This can produce rejects,or at least considerably aggravate handling of such a hose piece.Subsequent widening or calibrating processes often produce breaks at thewelded stitch seams in the longitudinal direction of the hose piece,which may extend over one or even more windings of the metal layers ofthe hose.

DE 198 51 173 C1 discloses a further method and a device for producingconnecting ends on metal hoses of the above-mentioned type. The metallayers of the hose are also fixed by laser welding before the separatingprocess, wherein a laser beam is guided continuously over the entireperiphery of the hose piece thereby superposing a cyclic motion whichsubtends a finite angle with respect to the peripheral direction of thehose piece to produce the welding seam and generate an approximatelysinusoidal or saw-tooth-shaped welding seam. This permits more effectiveand faster fixing of the metal layers in the region of the connectingends of the hose piece and effectively prevents extensive splashingwhich occurs, in particular, during point welding. It however, alsobears the danger that one or more metal layers are torn in the region ofthe connecting ends, in particular, during later widening or calibrationprocesses of a hose piece produced in this manner.

It is therefore the underlying purpose of the invention to provide asimple and inexpensive method of the above-mentioned type whicheliminates the described disadvantages and permits, in particular,perfect and load-resistant connection of the metal layers of theproduced hose piece in the region of the connecting ends. The inventionalso concerns a hose piece produced in this manner.

SUMMARY OF THE INVENTION

A process control object is achieved in accordance with the inventionwith a method of the above-mentioned type in that for fixing the metallayers in the region of the point of separation, at least one weldingseam, which extends at least about part of the periphery of the hose, isfixed through roller seam welding.

The term “roller seam welding” used throughout the specification andclaims refers to a weld seam produced in the following manner. Weldingelectrodes are constructed in the form of cylinders or rollers betweenwhich the workpieces to be welded are moved over at least part of theperiphery of the metal layers of a hose section or endless hose which isto be subsequently cut. A welding seam of a relatively large width canthereby be generated. The seam width can be defined by the width of theroller-shaped welding electrodes. In the inventive roller seam welding,the metal layers of the hose are welded together in a peripheral surfaceregion extending through the gap between the roller-shaped weldingelectrodes, with a pressing force being exerted on each of the rollersin a direction approximately normal to the hose. The welding current canbe controlled in a conventional manner e.g. through correspondingsetting of the pulse widths. The advance of the hose in the peripheraldirection thereof may be effected through a rotational motion of thehose itself and/or via the rotational speed of the roller-shaped weldingelectrodes, which rotate in opposite directions.

The invention provides, in particular for strip wound hoses, woven hosesand also extruded knitted hoses, chemical bonding connection, preferablythroughout a surface region of radially superposed parts or portions ofa hose which are already partially positively connected.

Undefined overlappings of the layers of such hoses (in particular up to4 non-uniformly oriented layers) are thereby prevented.

The inventive method permits extremely rapid and effective welding ofthe hose in the region of its connecting ends. In a preferredembodiment, a welding seam which extends along the entire periphery ofthe hose is provided by roller seam welding to fix the metal layers inthe separation region. Only one single welding seam is thereforesufficient for fixing the metal layers of the hose around the entireperiphery and may have a considerably larger width than a welding seamproduced through laser welding as defined by the width of theroller-shaped welding electrodes. The seam can withstand large loads, inparticular, in the axial and also radial directions of the hose.

Cutting of the hose piece from the correspondingly pretreated hose oflarger length or endless hose can be effected in a simple manner throughseparation in the region of the welding seam produced through rollerseam welding, wherein the welded metal layers of the hose piece arereliably and permanently fixed in the region of the connecting endsthereby safely preventing tearing of the hose piece in the region of theconnecting ends. This is also true, in particular, in the event ofsubsequent widening or calibration processes, wherein relatively largewidening of the connecting ends is possible without requiring annealingprocesses which are necessary in accordance with prior art in order toreverse the strain hardening produced during manufacture of the endlesshose. The continuous connection of the metal layers of the hose aboutthe entire periphery using roller seam welding moreover ensures uniformand regular connection of the individual layers throughout the entire,relatively wide connecting region of the layers such that a laterwidening or calibration process provides uniform distribution of loadswith, in particular, the elimination of load peaks which occursubstantially in punctiform or linear laser welding processes. Thethermal influence zone of the welding seam thereby extends over theentire width thereof and around the periphery of the hose such that anannealed structure is produced in this region which is favorable forsubsequent widening of the hose piece in the region of the connectingends, while avoiding the need for a separate annealing process. Finally,residual lubricants which could be produced during manufacture of thehose and which could otherwise cause disturbances when welding the hosepiece to an exhaust pipe e.g. of an automotive vehicle, are eliminatedby the roller seam welding process.

The width of the welding seam is preferably between approximately 2 mmand 12 mm, in particular, between approximately 3 mm and 8 mm. Thewelding seam is thereby sufficiently wide to provide simple separationof a hose piece in the region of the welding seam while assuringpermanent connection of the metal layers of the separated hose piece inthe region of its connecting ends.

In accordance with the inventive method, the welding seam extends aboutthe entire hose periphery or even only part thereof and can be disposedin a plane substantially perpendicular to the longitudinal central axisof the hose or in a plane which is inclined with respect to thelongitudinal central axis of the hose to obtain either a hose piecehaving a perpendicular or inclined connecting end or having oneperpendicular and one inclined connecting end, if required.

It is moreover suitable to separate the hose piece from the longer hoseor the endless hose after disposing the welding seam substantially alongthe central line of the welding seam which extends in the peripheraldirection of the hose, or at least in the vicinity thereof, such thatthe hose pieces obtained from an endless hose have correspondingconnecting ends.

The hose piece can be separated from the longer hose or the endless hosedirectly after roller seam welding and in the same operating cycle.Alternatively, the hose piece can be separated from the longer hose orthe endless hose after the welding seam has been completed, inparticular about the entire periphery of the hose. In the first method,the roller-shaped welding electrodes can be provided with a downstreamseparating means e.g. in the form of a mechanical cutting means, a laserbeam cutting means or the like to cut the hose piece directly afterroller seam welding of the metal layers thereof.

The hose piece can be cut from the longer hose or the endless hose inthe region of the welding seam in any conventional manner. In accordancewith a preferred embodiment, the hose piece is separated using beamseparation processes such as laser, plasma, water jet separation or thelike. In another preferred embodiment, the hose piece is mechanicallyseparated from the longer hose or the endless hose, e.g. throughcutting, melting separation or the like.

The invention also concerns a hose piece, in particular a strip woundmetal hose piece which comprises several metal layers and at least oneconnecting end in the region of which at least regions of theoverlapping metal layers are welded together. To solve the underlyingproblem of the invention, the metal layers of such a hose piece areroller seam welded together in the region of the connecting end over atleast part of the periphery of the hose piece. The metal layers arethereby roller seam welded together throughout a surface area region.The metal layers of the hose piece may thereby be continuously rollerseam welded to each other, preferably in the region of the connectingend and throughout the entire periphery of the hose piece. Such a hosepiece provides optimum durability in the region of its connecting ends.In particular, the formation of cracks in the region of its connectingends is reliably prevented.

The width of the welding seam in the region of the connecting end ispreferably between approximately 1 mm and 6 mm, between approximately1.5 mm and 4 mm, or approximately half the width of the endless hoseroller seam welding.

As mentioned above, the connecting end of the hose piece may extend in aplane which is oriented substantially perpendicular to the longitudinalcentral axis of the hose piece or in a plane which is inclined thereto.

In a preferred embodiment, both connecting ends of the hose piece areformed with metal layers which are roller seam welded together over atleast part of the periphery of the hose piece.

The invention is explained in more detail below using an embodiment withreference to the drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a schematic view of a strip wound metal hose (broken away)during roller seam welding of its metal layers;

FIG. 2 shows a top view onto a strip wound metal hose (broken away) inthe region of its roller seam welding;

FIG. 3 shows a connecting end (broken away) of a hose piece obtainedthrough separating the hose piece in accordance with FIG. 2 along theline III-III; and

FIG. 4 shows a hose cut to produce an inclined end.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a schematic view of a roller seam welding device 1. Thedevice 1 comprises two welding electrodes 2, 3 which are designed ascylinders or rollers and are each loaded with an electric voltage usinga welding transformer 4. The welding electrodes 2, 3 are disposed at amutual separation, and the workpieces which are to be welded togetherare introduced into the gap provided between the electrodes 2, 3. Theelectrodes 2, 3 can be loaded in a normal direction with respect to eachother (see arrows A) to provide the pressing force required during thewelding process. The electrodes 2, 3, which are designed as rollers, arerotatably disposed on their longitudinal central axis 5 and can rotateopposite to each other in the direction of the arrows B. The width ofthe welding electrodes 2, 3 and of the welding seam which can beproduced thereby is e.g. approximately 6 mm.

In the situation shown in FIG. 1, a metal hose 6 comprising severalmetal layers which are in mutual positive engagement with another isinserted between the welding electrodes 2, 3, wherein the electrode 2 isdisposed on the outer side and the electrode 3 is disposed on the innerside of the hose 6. To generate a welding seam which extends about theentire periphery of the hose 6, the hose 6 is rotated along itslongitudinal central axis 7 (FIG. 2) in the direction of the arrow C,thereby obtaining a welding seam 8 (shown in hatched lines) whose widthcorresponds to the width of the inserted roller-shaped weldingelectrodes 2, 3. The electrodes 2, 3 are thereby mutually prestressed inthe direction of arrows A and rotated in the direction of arrows B.

Alternatively, the hose 6 may be held stationary and the electrodearrangement 2, 3 may be moved around the periphery of the hose 6. Themetal layers of the hose 6 are thereby permanently connected to eachother in the region of the welding seam 8 throughout a surface arearegion.

FIG. 2 shows a top view onto the hose 6 in accordance with FIG. 1 whichwas provided with a welding seam 8 extending around the entire peripheryof the strip wound metal hose 6 and, in the present embodiment,substantially perpendicularly to the longitudinal central axis 7. Forcutting a hose piece 9 (FIG. 3) from the hose 6 in accordance with FIG.2, the hose piece 6 is cut in a central region of the welding seam 8, inthe present case along its central line III-III, in any conventionalmanner e.g. using laser beams.

The hose piece 9 of FIG. 3 obtained in this manner has a connecting end10 whose meal layers are joined to each other in the region of thewelding seam 8 in a permanent and reliable manner. The width of thisregion corresponds to approximately half the width of the welding seam 8disposed on the hose 6 in accordance with FIG. 2, wherein the width ofthe welding seam 8 may e.g. be approximately 6 mm and the width of theend-side region of the hose piece 9 where the metal layers of the hoseare connected may consequently be approximately 3 mm.

The surface connection of the metal layers in the region of theconnecting end 10 of the hose piece 9 obtained through roller seamwelding facilitates, in particular, further processing thereof, whereine.g. widening or calibration processes may be performed without thedanger that the hose piece 9 is torn in the region of its connecting end10. The opposite connecting end of the hose piece 9 which is not shownin FIG. 3 may have a corresponding design.

FIG. 4 shows a hose 6 with which a first connecting end is generated atcut line III-III within welding seam 8. The end thereby extends in aplane which is inclined relative to a longitudinal central axis 7 of thehose piece.

1. A hose piece having several metal layers in mutual positiveengagement with another, the hose piece being separated from a hose oflarger length or an endless hose, the hose piece comprising: a rollerwelding seam to fix radially superposed metal layers of the hose at aseparation region, said welding seam extending around at least a portionof a periphery of the hose within a plane which is substantiallyperpendicular to an axial extension of the hose, wherein the hose pieceis cut from the hose of larger length within an axial width of saidwelding seam to produce a first connecting end which remains within saidwelding seam throughout an entire periphery thereof.
 2. The hose pieceof claim 1, wherein said metal layers are continuously roller seamwelded together in a region of said first connecting end over an entireperiphery of the hose piece.
 3. The hose piece of claim 2, wherein saidwelding seam has a width in a region of said first connecting end ofbetween 1 mm and 6 mm.
 4. The hose piece of claim 3, wherein said widthis between 1.5 mm and 4 mm.
 5. The hose piece of claim 1, wherein saidfirst connecting end extends in a plane which is oriented substantiallyperpendicular to a longitudinal central axis of the hose piece.
 6. Thehose piece of claim 1, wherein said first connecting end extends in aplane which is inclined relative to a longitudinal central axis of thehose piece.
 7. The hose piece of claim 1, further comprising a secondconnecting end, said connecting end structured with characteristicsdefining said first connecting end in response to roller seam welding ofsaid second connecting end.